PROJECT:Lower Rear Grills. I elected this particular configuration (seen on a
race car)
for it's simplicity. To make the outer grills, first a cardboard pattern was cut
to the shape of the opening. Next, the pattern was traced onto expanded
sheet metal with a felt tipped marker. 1/2 inch allowance was made all around
the pattern to allow for a "lip" to be bent all around the part. The expanded sheet was
cut by hand using a tin snips then bent into shape using a medium sized vice
grips and a small bench vise. Each grill was made to precisely fit it's opening
and took about three hours to fabricate and mount.